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Installation of Body & Special Equipment Body Builders Guide I Body Builders Guide General Motors Isuzu Commercial Truck, LLC (GMICT) and American Isuzu Motors Inc. Is striving to provide you with the most up- to-date and accurate information possible. If you have any suggestion to improve the Body Builder's Guide, please call GMICT Application Engineering. In the West Coast call 1-562-229-5314 and in the East Coast call 1-404-257-3013 Notice of Rights All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic, mechanical, recording or otherwise, without the prior written permission. Notice of Liability All specifications contained in this Body Builders Guide are based on the latest product information available at the time of publication. The manufacturer reserves the right to discontinue or change at anytime without prior notice, any parts, material, colors, special equipment, specifications, designs and models. Made and printed in the USA. II Contents Introduction FMVSS EPA Requirements Weight Distribution Installation of Body & Special Equipment Glossary of Dimensions Clearances Weight Distribution Formulas Body Installations Recommended Weight Distribution Prohibited Attachment Areas Trailer Weight Subframe Mounting Performance Calculations Crew Cab Body/Frame Requirements Highway Limits Modification of the Frame Federal Bridge Formula Table Fluid Lines Electrical Wiring & Harnessing Commodity & Material Weights Maximum Allowable Current Approximate Weight of Commodites & Materials Exhaust System Fuel System Vehicle Specifications Index Rear Lighting NPR, NPR HD/W3500 W4500 Gas Servicability NPR, NPR HD/W3500 W4500 Diesel Wheelbase Alteration NQR/W5500 Diesel Hydraulic Brake System NPR, NPR HD NQR/W4500 W500 Crew Cab Diesel FRR/WT Body Application Summary Chart * FSR, FTR & FVR NPR, NPR HD/W3500 W4500 Gas NPR, NPR HD/W3500 W4500 Gas Cab Chssis Electrical NPR, NPR HD/W3500 W4500 Diesel NPR, NPR HD NQR/W3500 W4500 Diesel Cab Chssis Electrical NQR/W5500 Diesel NPR HD NQR/W4500 W500 Crew Cab Electrical NPR HD, NQR/W4500 W500 Crew Cab Diesel * FRR, FSR, FTR & FVR Cab Chassis Electrical FRR/WT *Note: 2002 FSR, FTR and FVR Mechanical & Cab Specifications Engine Horsepower & Torque Chart GVW/GCW Ratings Rear Frame Height Chart Clutch Engagement Torque Paint Code Chart * N/W Series Towing Procedure FRR/WT Series Towing Procedure FSR, FTR & FVR Series Towing Procedure Weight Distribution Concepts Weight Restriction Gross Axle Weight Rating Weighing the Vehicle Tire Inflation Center of Gravity III IV Introduction This guide has been provided as an aid to final stage manufacturers in determining conformity to the applicable Emission Control and Federal Motor Vehicle Safety Standards. Final stage manufacturers should maintain current knowledge of all Emission Regulations and Federal Motor Vehicle Safety Standards and be aware of their specific responsibility in regards to each standard. Any manufacturer making material alterations to this incomplete vehicle during the process of manufacturing the completed vehicle should be constantly alert to all effects, direct or indirect, on other components, assemblies or systems caused by such alterations. No alterations should be made to the incomplete vehicle that directly or indirectly results in any either component, assembly or system being in nonconformance with applicable Emission Regulations or Federal Motor Vehicle Safety Standards. General Motors Isuzu Commercial Truck, LLC (GMICT) and American Isuzu Motors Inc. will honor its warranty commitment (for the cab-chassis only), to the ultimate consumer, provided: (1) the final stage manufacturer has not made any alterations or modifications which do not conform to any applicable laws, regulations or standards, or adversely affect the operation of the cab-chassis; and (2) the final stage manufacturer complied with the instruc- tions contained in this guide with respect to the completion of the vehicle. Otherwise, the warranty becomes the responsibility of the final stage manufacturer. The final stage manufacturer is solely responsible for the final certification of the vehicle and for compliance with Emission Control and Federal Motor Vehicle Safety Standards. The information contained in this guide has been provided for the final stage manufacturer’s information and guidance. This guide contains information pertaining to the NPR/W Gas, NPR/W Diesel, NQR/W Diesel, NPR HD/NQR/W Diesel Crew Cab and FRR/WT Series Chassis Cab and Janesville assembled FSR, FTR and FVR Chassis Cab. Following is a list of Federal Motor Vehicle Safety Standards applicable to those vehicles with a GVWR greater than 10,000 lbs. Please refer to the following chart. V FMVSS Chart NOTE: This chart is only a guide, for complete information please refer to "Document for Incomplete Vehicle” provided with each chassis. Chart Legend: A Incomplete vehicle; when completed will conform providing no alterations have been made affecting items covered by FMVSS regulations and "Document for Incomplete Vehicle. B Incomplete vehicle; when completed by the final manufacturer will conform providing it is completed in compliance with FMVSS regulations and "Document for Incomplete Vehicle." + Meets Canadian Motor Vehicle Safety Standards bearing same FMVSS number. 3 Canadian MVSS only. 4 Not applicable to truck or bus. 5 Not applicable to trucks with a GVWR greater than 10,000 LBS. VI EPA Requirements NPR/W Gas, NPR/W Diesel, NQR/W Diesel, NPR HD/NQR/W Diesel Crew Cab and FRR/WT Series Chassis Cab To assure that U.S.A. and Canada Emission Requirements are met, this Incomplete Vehicle must be completed in strict accordance with all instructions contained in this document, especially the following instructions which relate to: A. Exhaust emission related components B. Noise emission related components C. Labels [A] EXHAUST EMISSION RELATED COMPONENTS Compliance of this vehicle with EPA, California and Canada Requirements will be maintained providing no alterations are made to the components or systems identified below: 1) DIESEL VEHICLES 2) GASOLINE VEHICLES Injection Pump Vehicle Control Module (VCM) Injector and High Pressure Lines Fuel Management System Turbocharger Air Induction System Charge Air Cooler and Charge Ignition System Air Cooler Hoses Catalytic Converter System Engine Control Module (ECM) Positive Crankcase Ventilation System Engine Speed Sensor Exhaust Gas Recirculation System Engine Coolant Temperature Sensor Evaporative Emission Control System Intake Manifold Miscellaneous Items Used in Above Systems Catalytic converter and its location Variable swirl system Exhaust Gas Recirculation System ADDITIONAL CANADA MOTOR VEHICLE SAFETY STANDARD CMVSS NO. 1101-EMISSION DEVICE CMVSS NO. 1102-CRANKCASE EMISSION (GASOLINE ENGINE ONLY) CMVSS NO. 1103-EXHAUST EMISSIONS CMVSS NO. 1104-OPACITY (DIESEL ENGINE ONLY) CMVSS NO. 1105- EVAPORATIVE EMISSION (GASOLINE ENGINE ONLY) [B] NOISE Compliance of this vehicle with EPA and Canada requirements will be maintained providing no alterations are made to the components or systems. CMVSS NO. 1106-NOISE This incomplete vehicle, when completed, will conform to the above standards except CMVSS-1106 providing no alterations are made which effect the function, physical or mechanical properties, environment, locations or vital spatial clearances of the components identified below: * Engine assembly Exhaust emission control system P.C.V. system (if equipped) * Intake system * Exhaust system Fuel system (if equipped) * Transmission assembly * Axle * Tires * Fan and drive Diesel fuel injection controls (if equipped) Turbocharger and associated controls (if equipped) * Catalytic converter and its location Variable swirl system (if equipped) VII Conformity with CMVSS 1106 is not determined solely by the design of the incomplete vehicle. When completed, it should conform to CMVSS 1106 providing no alterations are made to the noise attenuation components identified thus * in the above list. [C] LABELS The Emission control related information labels which are permanently affixed are required by government regulation and must not be obstructed from view or defaced so as to impair its visibility or legibility. PART 3 : Radio Noise CANADIAN RADIO INTERFERENCE REGULATIONS [A] The following statement is applicable to NPR/W Series Chassis-Cab (Gasoline Engine Only). This incomplete Vehicle, when completed, will conform to the above regulations providing no alterations or substi- tutions are made which affect any parts or components identified below: A. Distributor B. Ignition Wires C. Spark Plug Wires FSR, FTR & FVR U.S. ENVIRONMENTAL PROTECTION AGENCY AND STATE OF CALIFORNIA EMISSION REQUIREMENTS To assure that EPA and California Emission Certificate Requirements are met, this incomplete vehicle must be completed in strict accordance with all instructions contained in this document, especially the following instructions which relate to: A. Exhaust emission related components B. Labels [D] EXHAUST EMISSION RELATED COMPONENTS Compliance of this vehicle with EPA and California Certification Requirements will be maintained providing no alterations are made to the components or systems identified below: 1. DIESEL VEHICLES Injection Pump Injector and High Pressure Lines Turbocharger Charge Air Cooler and Charge Air Cooler Hoses Engine Control Module (ECM) Engine Speed Sensor Engine Coolant Temperature Sensor (6HE1-TC only) Intake Manifold Catalytic converter and its location (6HE1-TC only) Air cylinder for variable swirl system (6HE1-TCS only) [E]
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